KTM 250 400 450 520 525 SX MXC EXC 2000-2003 Repair Manual

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This manual covers the SX, MXC, and EXC models produced between 2000 and 2003, featuring engine variants of 250cc, 400cc, 450cc, 520cc, and 525cc. These motorcycles are recognized for their...

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Type: Motorcycle

Vendor:

Sku: 54991

Tags: 2000 2001 2002 2003 250 EXC 250 MXC 250 SX 400 EXC 400 MXC 400 SX 450 EXC 450 MXC 450 SX 520 SX 525 EXC 525 MXC 525 SX ATV KTM Motorcycle Powersports

Product variants

Description

This manual covers the SX, MXC, and EXC models produced between 2000 and 2003, featuring engine variants of 250cc, 400cc, 450cc, 520cc, and 525cc. These motorcycles are recognized for their robust off-road racing heritage and performance-focused engineering. These models have been developed with a commitment to reliability and are designed for demanding motocross, cross-country, and enduro riding environments. The SX, MXC, and EXC lines represent a consistent evolution in motorcycle technology, incorporating advancements in engine performance, suspension, and chassis design to meet the needs of competitive riders. This comprehensive workshop repair service manual provides in-depth information for owners and technicians. It covers all essential aspects of maintenance, repair, and diagnostics, including detailed procedures for the fuel system, cooling system, engine top end, clutch, lubrication system, engine removal and installation, crankshaft and transmission, wheels and tires, final drive, brakes, suspension, steering, frame, and the electrical system. With factory-level data, this manual empowers users to perform a wide range of tasks, from routine upkeep to complete engine rebuilds, ensuring the longevity and optimal performance of their motorcycles while potentially reducing repair costs.

🏷️ Basic Information

Identification

Make:

Model:

SX, MXC, EXC

Applicable Years:

2000, 2001, 2002, 2003

Engine Variants Covered:

250cc, 400cc, 450cc, 520cc, 525cc

Codes

Engine Codes:

Not specified, but manual covers specific engine variants.

Generation

Model Generation:

Manual covers specific generation of KTM SX, MXC, and EXC models.

👋 Introduction

Market Position

Target Audience:

Owners of KTM 250, 400, 450, 520, and 525 SX, MXC, and EXC models from 2000-2003 seeking to perform maintenance, repairs, and diagnostics.

Competitive Analysis

Advantage:

Provides factory-level information identical to what professional repair shops use, enabling significant cost savings on repairs.

Key Features

Completeness:

Complete and intact, with no missing or corrupt parts/pages, covering all models/engines/trims/transmission types within the specified years.

Delivery Method:

Instant Download - no shipping costs or waiting time.

Value Proposition

Cost Savings:

Enables users to perform repairs themselves, potentially saving hundreds or thousands of dollars in labor costs.

📋 Manual Details

Coverage Areas

General Information:

Included

Fuel System:

Included

Cooling System:

Included

Engine Top End:

Included

Clutch:

Included

Engine Lubrication System:

Included

Engine Removal Installation:

Included

Crankshaft Transmission:

Included

Wheels Tires:

Included

Final Drive:

Included

Brakes:

Included

Suspension:

Included

Steering:

Included

Frame:

Included

Electrical System:

Included

Wiring Diagrams:

Included

Troubleshooting:

Included

Appendix:

Included

Page Count

Estimated Page Count:

Hundreds of pages (specific count not provided, but described as comprehensive).

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Complete engine overhaul including top end, lubrication, crankshaft, and transmission.

Fuel And Cooling:

Detailed coverage of fuel delivery, carburetor/injection systems (as applicable), and the cooling system.

Chassis And Drivetrain:

Includes information on wheels, tires, final drive, brakes, suspension, steering, and frame.

Electrical System:

Comprehensive coverage of the electrical system, including detailed wiring diagrams and troubleshooting.

Procedures Included

Maintenance:

Routine maintenance tasks, fluid checks and changes, filter replacements, and general upkeep.

Repair:

Step-by-step repair procedures for all major components and systems.

Troubleshooting:

Diagnostic procedures for identifying and resolving common and complex issues.

Disassembly Assembly:

Detailed instructions for dismantling and reassembling various vehicle components.

Installation:

Procedures for installing new or replacement parts.

Technical Depth

Depth:

Professional level, suitable for experienced technicians and serious DIY mechanics. Covers everything from basic adjustments to complete engine rebuilds.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printable:

Full Printable

Zoom Capability:

Zoom IN/OUT enabled

Binding Type

Binding:

Digital Download (no physical binding)

Paper Type

Paper Type:

N/A (Digital Format)

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke (likely liquid-cooled, details within manual).

Displacement Options:

250cc, 400cc, 450cc, 520cc, 525cc

Performance

Horsepower Torque:

Specific figures vary by engine displacement and model, detailed within the manual.

Fuel System

Fuel Delivery:

Likely carburetor-based for this era, but manual will specify exact type (e.g., Keihin, Mikuni) and settings.

Ignition System:

Details on ignition timing, spark plug specifications, and troubleshooting provided.

Lubrication

Oil Type Capacity:

Specific oil grades (e.g., Motorex) and capacities for engine and transmission are detailed.

Cooling

Cooling System Type:

Liquid-cooled (radiator, fan, coolant specifications).

🔧 Transmission

Standard

Transmission Type:

Manual, multi-speed (specific number of gears depends on model, typically 5 or 6-speed).

Optional

Transmission Options:

N/A (single transmission type per model variant).

Features

Clutch Type:

Hydraulically actuated wet multi-plate clutch (details on operation, maintenance, and rebuild).

Gear Ratios:

Specific gear ratios for each model variant will be provided in the manual.

Transmission Fluid:

Type and capacity of transmission oil (often shared with engine oil in KTMs of this era).

📐 Dimensions

Exterior

Overall Dimensions:

Varies significantly by model (SX, MXC, EXC) and engine displacement. Detailed dimensions not provided in product info.

Weights

Dry Weight:

Varies by model and engine size. Manual will provide specific weights.

Wet Weight:

Varies by model and engine size. Manual will provide specific weights.

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable to off-road motorcycles in the same way as passenger vehicles.

Active Features

Braking System:

Hydraulic disc brakes front and rear. Manual provides specs and servicing procedures.

Passive Features

Frame Construction:

Chromoly steel trellis frame (details on inspection and repair).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Off-road motorcycles typically do not feature infotainment systems).

Driver Assistance

Rider Aids:

N/A (Basic rider controls, no electronic rider aids like traction control or ABS).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Detailed in manual; typically every 10-20 hours of riding or annually.

Air Filter Cleaning:

Frequent cleaning recommended, specific intervals in manual.

Valve Clearance Check:

Specific intervals provided in the manual, crucial for engine health.

Fluid Specifications

Engine Oil:

Recommends specific grades and brands like Motorex Power Synt 4T or equivalent SAE 10W-40 or 15W-50 (check manual for exact specification).

Coolant:

Specific antifreeze/coolant mixture (e.g., 50/50 distilled water and ethylene glycol based coolant).

Brake Fluid:

DOT 4 brake fluid is typically specified.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve seats, wheel bearings, chain and sprockets are common wear items for off-road bikes of this era.

Electrical Connections:

Corrosion on electrical connectors can be an issue in off-road environments; manual covers inspection and maintenance.

📚 Vehicle History

Brand Heritage

Ktm Heritage:

KTM is renowned for its off-road racing heritage and performance-oriented motorcycles.

Model Evolution

Sx Mxc Exc Evolution:

These model lines have consistently evolved with advancements in engine technology, suspension, and chassis design for motocross, cross-country, and enduro riding respectively.

Production

Production Period:

2000-2003

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

KTM models from this era were highly regarded in their respective categories (motocross, enduro) and often won races and industry accolades. Specific awards for these exact model years are not detailed in the product description.